Track Spiders Robotic System

ABSTRACT

The present invention relates to one or more Track Spider robots moving on an overhead track in a non-industrial environment like home, patient care, shopping places or pharmacies. The system can be wirelessly controlled using a computer, a hand held remote or voice commands. The purpose of this invention is to free up the ground space and move unobstructed overhead even in cramped spaces. Depending on the attachments available on the Track Spider robots, each can be configured to perform independent tasks in confined spaces. It can be used to fetch or deliver objects using object identification techniques, or to carry loads from one point to another, to deliver medicines or instructions in a patient care environment, as a store assistant or as a roving security camera, to name a few uses.

A spider while moving on the ceiling can descend vertically using aspider thread to any point in space and can then climb back up and movehorizontally on the ceiling to another point. Similarly, each of theserobots moves on an overhead track system and descends vertically using adescending mechanism (“Spider Thread”) to a point in space under thetrack. The first part of the name (“TRACK”) is driven from the use oftracks. The second part of its name comes from a spider because of theability of the bottom part of the robot to descend and ascend in spacelike a spider. Each robot can perform tasks as defined later in thisdocument and roll back up and then move to the next point on the track.Additionally, unlike a spider, it may also move horizontally whilehanging from its “Spider Thread”. This invention allows one or pluralityof Track Spider Robots to be working in one environment independently orin collaboration with other robots using wireless communication withoutusing up floor space.

BACKGROUND OF THE INVENTION

In homes, shops or pharmacies, it is often desired to get a helping handthat can fetch or deliver objects from one point to anotherautomatically. For example, in a pharmacy, this robotic invention can beused to fetch medicines from shelves to the pharmacist or directly tothe customer based on the information fed to the robot by the controlsystem (for example a computer). This invention consists of one orplurality of Track Spider Robots each moving on an independent orconnected track sections forming a Track System. The Track SpiderRobot(s), the Track System, Power Supplies and the Master ControlSystem—all put together form the Track Spider Robotic System. Thisinvention moves the robots overhead thereby freeing up the floor space.Using the “Spider thread”, a Track Spider robot can descend or ascend innarrow spaces, for example between aisles, and perform its task e.g.placing or picking up one or more objects. Each robot can be configuredto perform a certain task at a given point in space using robotic armsor any other tool that can be attached to a robot. In this document thereference to a robot would mean one Track Spider Robot. However, one orplurality of Track Spider Robots may be present in one Robotic System.

SUMMARY OF THE INVENTION

The present invention relates to one or plurality of Track Spider Robotsmoving on an overhead Track System in a non-industrial environment likehome, patient care, shopping places or pharmacies. Each Track Spiderrobot includes multiple DC motors and Servos controlled by multiplemicroprocessors. Each Track Spider Robot wirelessly receives the controlcommands from the Master Control System.

The purpose of this robot is to free up the ground space and moveunobstructed overhead in a non-industrial environment like shops,pharmacies, homes and patient care environments. This invention can workas a pharmacist assistant or a shop assistant or as a helping hand in ahome or patient care environment or to carry a security surveillancecamera. Depending on the attachments available on the robots, each canbe configured to perform tasks in confined spaces. Some of the examplesof the uses this invention may be put to are as follows:

-   -   1. Fetching or delivering objects from one point in space to        another in a home environment or shops or pharmacies.    -   2. Arranging shop or pharmacies items on shelves.    -   3. Deliver medicines, instructions to patients    -   4. Monitor patients or kids remotely using a video camera.    -   5. Roving Security Camera    -   6. Inventory Management    -   7. Perform any other task that can be performed by the tools        (e.g. robotic arms) attached to the robot.

The above is not an exhaustive list of uses but just a sample of usesthis invention can be put to.

The Track Spider Robotic System consists of the following sub systems:

-   -   1. Track System (Parts 4, 5, 6, 7, 21 in FIG. 1 and all parts        shown in FIG. 2)    -   2. One or plurality of Track Spider Robots (Parts 1, 2, 3, 8, 9,        10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 22 in FIG. 1 are for one        Track Spider Robot)    -   3. Master Control System that consists of the control software        running on a computer or a hand held device. The commands from        the computer or a hand held device are transmitted using radio        frequency to each of the Track Spider Robot in the system. Each        Track Spider Robot is also capable of similarly transmitting        information to the Master Control System. The Master Control        System is also referred to as the Master Controller in this        document.    -   4. Power Supplies that provide 12 volt to 48 volt regulated        power. The number of Track Spider Robots in the system        determines the current capacity of a power supply.

To understand the structure, each Track Spider Robot can be divided intothe following assemblies:

-   -   (1) Drive Assembly (Parts 1,2,3 and 8 as shown in FIG. 1): The        major parts belonging to this section are the drive wheels        assembly, the motors to power the wheels, the power collection        brushes and the mechanism to calculate the incline of the track.    -   (2) Control Section (Part 9 as shown in FIG. 1): This section        contains chargeable batteries and electronic parts including the        logic circuits, power regulation circuits, temperature control        assemblies for this section. The section contains the assembly        to turn the “Spider Section” (bottom section) about a vertical        axis. The “Spider thread” (part 10 as shown in FIG. 1) is the        mechanism to lower or raise the bottom section. Alternate        methods can be used to replace the mechanism shown in Part 10,        FIG. 1.    -   (3) Spider Section (Parts 11, 12, 13, 14, 15, 16, 17, 18, 19 and        22 as shown in FIG. 1): The Spider Section is the bottom portion        of a Track Spider Robot. This Section is the part of a Track        Spider Robot that ascends or descends to a point in space. This        section consists of the Instrument Panel (Part 18 in FIG. 1) and        a Tool and Storage Section under it. The instrument panel        contains one or plurality of each of the following: light        source, microphone, front and bottom distance rangers, camera        device, a speaker unit and local control keypad. The Tool        Section houses the robotic arms and storage space for objects on        board.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features of the invention will be more readily understoodby reference to the following detailed description, taken with referenceto the accompanying drawings, in which:

FIG. 1: Depicts the system overview of one Track Spider Robot mounted onan overhead Track System section. Experts would agree that this is justan illustration and this invention can be manufactured in differentshapes without deviating from the true scope of the invention.

FIG. 2: Depicts the plan of a section of the Track System on which aTrack Spider robot moves. This figure also shows a Track Section thatallows the robots to make a turn and move from one track to another.

FIG. 3: Depicts the command execution logic for a Track Spider Robot.

DETAILED DESCRIPTION OF PARTS

Track System (Part 4, 5, 6, 7 and 21 FIGS. 1 and 2, Part 20 in FIG. 2):Consists of one or plurality of hollow sections having a gap at thebottom center through which a Track Spider Robot hangs and the bottomportion is flat to provide a rolling surface to a Track Spider Robot.Multiple sections of the tracks can be connected together using theTurning Track Section (Part 20, FIG. 2) that allows a Track Spider Robotto move from one track to another. A Track Spider Robot may need to moveto another track section either to reach its destination or to provideway to another passing Track Spider Robot. Each track section is mountedoverhead to the ceiling or some other overhead structures.

Guide Bars (Part 5, FIGS. 1 and 2): This is a set of guide bars attachedto the tracks. The drive wheels roll over the two guide bars one each oneach side of the track. The guide bars prevent a Track Spider fromhitting the track enclosure (Part 7) while in motion. The guide bars, inconjunction with the motor braking system, also prevent a robot fromreactionary turning on its wheels when the Spider section is turningabout its vertical axis. The guide bars and the drive wheels grooves maybe toothed so that they can work like a rack and pinion combination.

Track Information (Part 6): The track markings and sensors together arecalled the Track Information. The Track Information helps the robot toidentify its location, to decide speed and the direction of motion.Track information may also be used to trigger “an event” that can beused to perform a certain action (for example blowing a horn) on behalfof the robot. In FIGS. 1 and 2, the track information is shown asparallel straight lines, but in reality these will be bar codes thatwill carry information like the location, speed limits, geographicaldirection and action information to name a few. Action information, forexample, may include information for a Track Spider Robot to give alight or sound signal at certain locations of the track. Also, thistrack information is not provided on the entire length of the TrackSystem. An information piece is provided on the track only when certaininformation, e.g. speed limit, is different from the previousinformation on the track. In the absence of the information, a TrackSpider Robot continues to use the last information read from the track.

Track Enclosure (Part 7): This is the track enclosure, shown astransparent in FIG. 1 for the purpose of illustration only. Thisenclosure covers the Drive Assembly of a Track Spider Robot. Theenclosure is attached to the overhead mounting surface (for example—aceiling).

Track Crossing: (Part 20 FIG. 2): The track-crossing unit consists ofsmall track sections attached to the main tracks. Each crossing unitconsists of sections of guide bars (Part 5 FIG. 1 and FIG. 2). Thelayout of the guide bars allows the robot to travel straight or to turnabout a perpendicular axis that passes through the intersection of thegap between the tracks. The crossing unit may also contain the trackinformation (Part 6, FIG. 2). In FIG. 2, the track-crossing unit shownallows the robot to take a turn equal to multiple of a right angle or tomove straight without a turn. Other crossing units may allow the robotto turn by any angle greater than or less than a right angle. If a TrackSpider robot in the system needs to move on to another track, either toreach a destination or to allow another robot in the system to pass it,the Track Spider robot comes and stops at the intersection at the centerof the track-crossing unit. Then both the Track Spider robot wheels movein opposite directions allowing the Track Spider robot to turn about avertical axis. Once the robot has moved enough to face the track itneeds to move on to, the turning motion stops and both the robot wheelsmove in the same direction to carry the robot on the next track.

Part 21: These are Power Strips attached to the track on each side ofthe bottom gap and insulated from the main body of the Track System.These Power Strips carry a 12V to 48V electric power. Power collectiondevices attached to a Track Spider Robot collect the power to charge thebatteries onboard.

Drive Assembly: This assembly consists of the following main parts:

Drive Wheels (Part 1): This is one of the two drive wheels attached to aTrack Spider Robot. Each drive wheel contains a groove on thecircumference. This groove allows the robot to roll over the guide bar(Part 5) attached to the tracks (Part 4).

Part 2: This is the drive mechanism housing which contains one or moreDC motors to power the drive wheels (Part 1). A motor may drive eachdrive wheel (Part 1) independently such that each of the drive wheelscan have a different speed and direction of rotation. This section alsocontains a “plumb line” assembly to calculate the inclination angle ofthe track on which the robot is moving. This inclination angle is usedto calculate the actual horizontal distance moved by the robot. Theinclination angle of the track may also be marked on the track as partof the information shown in part 6 in FIG. 1 and FIG. 2.

Part 3: Part 3 is the pivot assembly that connects the Drive assemblywith the rest of the robot. This pivot assembly allows the portion ofthe robot under the tracks to sway when the robot is maneuvering a turn.This swaying motion prevents movement of objects or spilling of liquids,which might be onboard, inside the bottom portion of the robot bycounteracting the centrifugal force.

Control Section (Part 9 in FIG. 1): This section consists of thefollowing four main sub assembly types, each of which is described inmore detail below:

-   -   (1) Electronics    -   (2) Batteries    -   (3) Turning Assembly    -   (4) Spider Thread Movement Assembly

Electronics: The major electronic parts in this section are:

-   -   (1) Programmable Integrated Circuits    -   (2) Memory Chips    -   (3) Motor controllers    -   (4) 12 C Bus for communication between different circuits    -   (5) Battery charging and monitoring circuits    -   (6) Voltage regulating circuits    -   (7) Temperature control circuits    -   (8) Load monitoring circuits    -   (9) Voice synthesizing units    -   (10) Transceivers to communicate with the Master Control System        or to communicate with other robots in the system.

The logic on board each Track Spider robot provides intelligence forrobotic functions and act as a backup intelligence in case communicationlink from the Master Control System is broken. If the communication linkis broken, this logic periodically attempts to establish the link.

Batteries: The batteries on board each Track Spider Robot are used topower its systems. These batteries are charged by the power collectedfrom the Power Strips (Part 21 FIG. 1 and FIG. 2) mounted on the TrackSystem. This system enables uninterrupted and regulated power supply toeach of the Track Spider Robot in the system.

Turning Assembly: The turning assembly consists of a worm and worm wheelassembly driven by a Servo or a DC motor. The “Spider Thread” (Part 10in FIG. 1) is connected to the worm wheel that turns the Spider Section(Part 15 FIG. 1, the lower portion of the Track Spider robot) when theworm wheel turns. The worm wheel also moves an encoded wheel that isused to calculate the amount of rotation of the Spider Section.

Spider Thread Movement Assembly: This is an electrically, pneumaticallyor hydraulically powered system that is used to expand or contract thetelescopic arm (part 10 in FIG. 1). The Telescopic arm can be retractedand even moved up to the Pivot Assembly (Part 3 in FIG. 1) to gainmaximum clearance from the floor.

Spider Section: (Parts 11, 12, 13, 14, 15, 16, 17, 18 and 19 in FIG. 1)This section, is the part of the Track Spider Robot, which moves down toa point in space or is raised back up similar to the movement of aspider. This section hosts a set of one or plurality of robotic arms toperform a task at a point in space. The robotic arms as they areenclosed in the Spider section when the Track Spider is in motion. Thissection, in advanced versions, also consists of bar code readers andobject identification techniques. This is most useful in a pharmacy or ashopping environment where the objects are bar coded. The robotic armscan pick up or place one or more objects in the storage space. The topportion of the Spider Section is called the Instrument Panel (Part 18,FIG. 1). The Instrument Panel consists of at least the followinginstruments and sensors:

-   -   (1) Microphone (Part 11, FIG. 1) A microphone is also connected        to this section, which may be used by the user to send voice        messages or commands back to the master controller.    -   (2) Range finders (Part 12, FIG. 1): The range finders are can        be infrared or ultra sonic units used to calculate the distance        of any obstacles in the path of the robot. One set of range        finders is also attached to the bottom surface of the Spider        Section. These bottom range finders are used to detect an        obstacle in the vicinity of the robot when the Spider Section is        being lowered.    -   (3) Camera unit (Part 13, FIG. 1): The camera unit is used to        collect live video from the location of the robot.    -   (4) LCD Display unit (Part 16, FIG. 1): A fixed LCD display unit        is mounted on the bottom section to display status messages        about the robotic system or to display messages broadcast by the        Master Control System or other Track Spider robots in the        system.    -   (5) Keypad (Part 17, FIG. 1) The keypad to input commands when        the Track Spider robot is stationary. This keypad is activated        only when the correct access code has first been put in.    -   (6) Speaker (Part 14, FIG. 1) The speaker that is used to play        audio signals or messages to the user. The speaker is also used        to play signals to warn anyone in the vicinity of a moving Track        Spider Robot.    -   (7) Light Source (Part 19, FIG. 1): light to illuminate the work        area, if required.    -   (8) Optional Flashing lights to warn the people in the vicinity        of a moving Track Spider Robot.

Experts would agree that the above list of items available on theInstrument Panel is not exhaustive. The number of each of the aboveitems may also differ based on the requirements. The location of each ofthe items may be different from the location shown in FIG. 1.

The Spider Section also has hooks, attached to the bottom surface, whichcan be used to hang loads up to the permissible total load limit.

Command Execution Logic: The Command Execution Logic for a Track SpiderRobot is shown in FIG. 3. The Track Spider Robot continuously sendsupdate status to the Master Controller using the wireless link. If anyof the onboard sensors on the Track Spider Robot, or the information onthe Track System, requests an interruption of the action in progress,the same is communicated to the Master Control System. The MasterControl System then decides if the interrupt should be ignored or not.If the interruption request needs to be ignored, the Track Spider Robotcontinues what it was doing. If the interruption request cannot beignored, the Master Control System evaluates the information and sendsan alternate action command to the Track Spider Robot. The alternateaction command then follows the same command execution logic asdescribed above.

This invention receives commands from and sends status information tothe Master Control System using a wireless link. The input from the usercan be either using a computer or a hand held wireless remote or usingvoice commands or the keypad mounted on the robot itself. The input fromthe user can also be in a form a script that executes automatically inreaction to a system event or a time event. A system event is raisedwhen a robot, for example, has reached a destination or has detected aproblem in the track. These were just examples and the user is free touse the scripting to create many complex commands or reaction to events.The Master Control System can send independent commands to one or allthe robots simultaneously.

Safety Features: The most important safety features that form part thisinvention are:

-   -   (1) Multiple sensors mounted on the Spider section control the        speed of the Track Spider robot if the robot is in proximity of        an object or person. If required, the Track Spider robot is        capable of stopping before hitting an object or person. The        sensors also prevent the Spider section from descending if they        detect an object or person that can be hit during the descent.    -   (2) Using the track mark and sensors (Part 6 FIG. 2), control        the speed of each Track Spider Robot to prevent accidents.    -   (3) In the default mode, a Track Spider robot does not move        until the Spider Section is pulled up again.    -   (4) The load sensors on the robot give an indication of the        amount of load applied to a Track Spider robot so that the user        can make use of the system with optimum performance and without        jeopardizing safety. If the load limit is exceeded an audio        alarm is sounded at the robot and an alert is raised at the        Master Control System also.    -   (5) Voice and sound signals provided to the user to announce        status messages, if configured to do so, or to announce alert        messages.    -   (6) Short circuit protections are built into the system.    -   (7) Each Track Spider robot carries a power switching circuit        that can be turned off to deactivate the robot.    -   (8) If the connectivity with the Master Control System is lost,        each of the Track Spider robots in the system can be configured        to a) stop where it is or to park at the designated location b)        create alarms and alerts c) use onboard logic for the tasks at        hand. This is just a sample of configuration options and can be        programmed to perform more complex reactions to loss of        connectivity with the Master Control System.

Master Control System: The Master Control System software, which can berun on a computer, is a graphical user interface (GUI). The MasterControl System may be used to wirelessly:

-   -   (1) Control one or more robots manually using computer keys or        mouse    -   (2) Move one or more robots forward simultaneously or        independently    -   (3) Move one or more robots backwards simultaneously or        independently    -   (4) Stop one or more robots simultaneously or independently    -   (5) Control the speed of one or more robots simultaneously or        independently    -   (6) Lower one or more robots at each of their locations to a        point in space below the track, simultaneously or independently    -   (7) Raise one or more robots at each of their locations to a        point in space below the track, simultaneously or independently    -   (8) Control the speed of descent of one or more robots        simultaneously or independently    -   (9) Control the speed of ascent of one or more robots        simultaneously or independently    -   (10) Stop the ascent or decent of one or more robots        simultaneously or independently    -   (11) Locate the location of each robot in the system at any        given point of time    -   (12) Track the path traversed by one or more robots in the        system    -   (13) Track the path to be traversed for a given task(s) for one        or more robots in the system    -   (14) Program one or more robots to perform a task independently        or in conjunction with each other.    -   (15) Schedule the execution of programs or scripts    -   (16) Based on events generated by actions by one or more robots,        execute additional scripts or tasks on one or more computers in        the network,    -   (17) Based on events or scheduled, send emails or phone calls        about the status of each robot to one or more recipients.    -   (18) Enable the control of one or more robots from the Internet.    -   (19) Broadcast status messages or still pictures or video from        the camera mounted on one or more robots independently or        simultaneously.    -   (20) “Park” one or more robots at designated locations on the        track when not in use.    -   (21) Other capabilities of the Master Control System Software        are:    -   (22) It can decide which robot is nearest to a point on the        track at which a robot is required and send that robot there if        it is not assigned a task already.    -   (23) It can support one or more robots in the robotic system.    -   (24) It can be expanded to talk to and coordinate more than one        robotic system, if required.    -   (25) It can monitor the status of each robot in the system and        generate user reports.    -   (26) It can draw a chart depicting the distance of objects in or        around each robot on the system.    -   (27) It can detect the health status of each robot in the system        and automatically configure itself by automatically finding the        number of active robots in the system.    -   (28) It can be used for receiving live video from one or more        robots independently or simultaneously.    -   (29) It can be used for inventory management.

The above list of functions that can be performed by the Master ControlSystem is not exhaustive and can be modified to perform additionalfunctions. The Master Control System Software and the logic softwareonboard each robot may be stored in memory device, such assemiconductor, magnetic, optical or other memory devices and may betransmitted using any communication technology, such as optical,infrared, microwave, radio frequency or other transmission technologies.It is expected that such computer program or processor logic can bedistributed as a removable media with accompanying printed or electronicdocumentation, pre loaded with a computer system or distributed from aserver or electronic bulletin board over the Internet.

What is claimed is:
 1. A Track Spiders robotic system comprising of oneor plurality of Track Spider robots, an overhead Track System formovement, a drive assembly for each Track Spider robot and consisting oftwo grooved wheels, a Control Section, an electric, hydraulic orpneumatic telescopic arm to raise or lower the Spider Section whichconsists of an instrument panel, robotic arms and a storage area, suchthat the Master Control System can be used to move the Spider Section toany point in space under the track and perform an action around thatpoint in space.
 2. The Track Spiders robotic system according to claim1, which can be used in a non-industrial environments like shops,pharmacies, homes and patient care environments.
 3. The Track Spidersrobotic system according to claim 1, wherein the tracks information isused to inform each Track Spider robot about the locationidentification, geographical direction of that section of the track,permissible speed limits for the robots, inclination angle of the trackand information about any task a robot should perform when passing overa point on the track.
 4. The Track Spiders robotic system according toclaim 1, wherein the tracks can cross each other such that each robotcan move from one track to another.
 5. The present invention may beshaped or constructed in other specific forms without departing from thetrue scope of the invention. The described shape is to be considered inall respects only as illustrative and not restrictive.